Melted Appliancelinc

[jpoje]

What would cause an appliancelinc to fail and melt? I've had many insteon devices just plain fail, but never experienced any of them melting or smoking. 

 

I had a simple vent fan connected to this appliancelinc for approximately 3-4 years. I controlled it with a keypadlinc button that triggered a 40 minute cycle when I would use my dryer (this vent fan is installed in the dryer vent to assist with dryer efficiency by assisting air flow through the dryer vent).

 

This fan would only run when I turned it on myself with keypadlinc and I would either manually turn it off myself or it would turn off itself via a 40 minute timer programmed in ISY. I also have a "nighttime" program that runs when I go to bed to ensure all devices in the home are turned off. 

 

Around 3:00am in the morning, I heard a strange noise, when I finally got up to see what the noise was, I realized it was the vent fan. I tried to turn it off by using the keypadlinc button, but fan would not turn off. I then went to turn off directly at the appliancelinc and saw smoke and smelled a horrible electrical smell. I immediately pulled the appliancelinc from electrical outlet to find this (see photo).

 

 

 

 

 

 

[paulbates]

What's the load of the fan?

 

Its probably worth taking the case apart and post pictures of the inside, someone here will probably be able to diagnose

 

Paul

[Techman]

The Appliancelinc is dated 2006 but it also appears to have an earlier date code sticker on it which seems strange.

 

Did your fan malfunction and overload the Appliancelinc or is the fan still working as it should?

[jerlands]

I'm interested in seeing the insides of it... I'm assuming Smarthome has no interest in it and probably would claim overloading it.

 

 

Jon...

[KeviNH]

Interesting failure mode,   Sounds like this: 
 

ApplianceLinc V2 Recall:SmartLabs Design has identified a potential defect in the product, which may cause the product to overheat. If this occurs a small portion of the
plastic case may melt. There has been no report of injury or damage.   The defect is characterized by the controlled load remaining in the "ON" position and not turning to the "OFF" position. Reports of this occurrence have been where the controlled device is one that creates an instant on load such as some fluorescent lights and small fans.   

Model # 2456S3 was part of the recall, but rev 1.3 shouldn't have this issue.

[Brian H]

Yes I had two smoke when the capacitors C17 and C18 across the relay contacts shorted and the load tried to run through the shorted capacitors. Was fixed at hardware 1.3. With the recall mentioned for the 2456S3. The 2856S3 Icons models was hardware 1.4

 

It would be interesting if you opened and could provide a photo.

 

That area is where C17 and C18 that would burn up where mounted. Should have been removed with the recall that started at V1.3.

It is also right over the Black wire AC Input, Red Load Output and the 120 volt AC Coil power relays output contacts. A failing connection or the relay could overheat also.

 

Case does look like it may have started nearer the top label area. In that case there is a 30 volt Zener diode that sometimes would fail. Sometimes in a burned area on the PCB and solder got hot enough for it to fall off the pads.

[jpoje]

I do not remember the load of the fan, but do remember when installing it, 3 or so years ago, that it was well below the 480W 15A specs on appliancelinc. Fan still works just fine, I just have to plug it in and out of the outlet to use it.

 

It would seem that the appliancelinc had to fail first?, ultimately turning on power to fan upon its failure, or something happened to have the appliancelinc turn on the fan in middle of night and may have ran continuously for several hours causing the overheating? The keypadlinc it is programmed to is functioning just fine. I live in Florida and do specifically remember that was our coldest night actually needing to run the central heating system that and that was the only thing that was different about that night.

 

I will take it apart and post pics. The 2006 marking on device seems strange, since I built home in 2009 and started installing the insteon products around 2011, unless it was one I happened to purchase "used" on ebay.

 

Thanks for the help, pics to follow.

[Brian H]

I had another thought.

I have had two of them start pulsing On and Off at about a one to two second interval. Main filter cap C2 had failed and the circuit started cycling.

I replaced C2 in both of them and they again where stable.

If the fan was pulsing On and Off at a short On Off cycle. That also could have made it fail.

 

I would suspect it was one of the used ones you got from eBay. My replacements from the recall exchange are one week older than yours. 0628 Rev 1.3

In 2011 the hardware revisions where in the  4.? range.

[jpoje]

Pics

 

 

[Brian H]

The attached photos are from a How To Modify a 2856S3 Icon On/Off module for a dry contact output. Same board in the V1 2456S3 version. Yellow lines are part of the mod information.

 

Not too easy to see what failed in your photos. If C17 and C18 where still in yours. They could have smoked but the size of the PC run to C17 would have burned off like a fuse and probably not done as much burning.

The component photo does show C17 and C18 along with the two heavy AC Line and Load wires soldered to relays contacts.

Solder side also shows the two heavy runs as it has plated through holes and both sides have a heavy run.

I suspect the relay failed or the solder connections got poor and overheated.

 

[jpoje]

Do you think my device was one of the "recalled" ones?  I would like to check the other appliancelincs in my home and remove them if they are the "recalled" ones, but do not know what to look for. Also, are the outdoor appliancelincs made any better than the indoor ones? Thank you for your help.

[jerlands]

Do you think my device was one of the "recalled" ones?  I would like to check the other appliancelincs in my home and remove them if they are the "recalled" ones, but do not know what to look for. Also, are the outdoor appliancelincs made any better than the indoor ones? Thank you for your help.

 

 

SmartLabs Design is announcing a voluntary recall and replacement program

on the ApplianceLinc V2 and ICON Appliance On/Off Module (product numbers

2456S3, 2856S3B, 2856S3).

 

Yours is V2 2456S3...

This notice was posted 07/14/2006 so whether or not they'll still honor it is questionable but wouldn't hurt to try.

 

Edit: I'd at least send them a photo

 

 

Jon...

[Brian H]

KeviNH had a link in his post to the Smarthome Forums thread.

Here it is in case you missed it.

http://forum.smarthome.com/topic.asp?TOPIC_ID=378

The link in that thread for the recall order form with date and version numbers no longer works.

Here is a text part of the file I have stored in Microsoft a mht type file. That I can't upload here.

 

"Note: Devices received after 7/1/2006 or with the following revision numbers are
not subject to this voluntary recall.
2456S3 revision 1.3 and above. 2856S3B, 2856S3 revision 1.4 and above."

 

2456S3 hardware 1.3 and above should be fine. The version 4.0 and above are a completely different design from the hardware version 1.3 models. The revision 4 models also have a protective network across the relay contacts that the 1.3 ones had removed. As they where the ones burning out when they shorted.

 

If you want to verify the version 1.3 modules you have. Look at my component.jpg photo and see C17 and C18 are in the photo near the edge of the PCB. If you take the top cover off of the 1.3 modules. They should not be there. Either cut off during the recall or never installed. If they are still in yours. Cut them out with a small wire cutter or gently bend them back and forth till the leads break off of the capacitors.

 

I found the FCC Database Files for the Dual Band Outside ApplianceLinc. It looks like it is designed well. Has the new switching power supply in it that uses less standby power and what looks like a very heavy duty relay. Don't have any so can't give personal feelings on it.

 

I am BLH in the Smarthome Forums  thread.

[jpoje]

I just received an outdoor appliancelinc today to replace the burnt device. Probably not worth the time sending photo to Smarthome, just want to remove any others I may have that were in the "recall". Thanks for the help

[Brian H]

You are welcome.

Have a better text file from the recall data.

 

            SmartLabs Design is
            announcing a voluntary recall and replacement program on the
            ApplianceLinc V2 and ICON Appliance On/Off Module (product numbers
            2456S3, 2856S3B, 2856S3).

            Customers affected by this program are eligible to receive a
            replacement product (ApplianceLinc V2 or ICON Appliance On/Off
            Module) at no cost.

            SmartLabs Design has identified a potential defect in the product,
            which may cause the product to overheat. If this occurs a small
            portion of the plastic case may melt. There has been no report of
            injury or damage.

            The defect is characterized by the controlled load remaining in the
            ON position and not turning to the OFF position. Reports of this
            occurrence have been where the controlled device is one that creates
            an instant on load such as some fluorescent lights and small fans.

            If you are in possession of product displaying this defect or would
            like a replacement product, please discontinue use and fill out the
            form below. SmartLabs Design is committed to providing highest
            quality products to our customers. We regret any inconvenience this
            matter may cause and appreciate your continued support.

            Note: Devices received after 7/1/2006 or with the following revision
            numbers are not subject to this voluntary recall.
            2456S3 revision 1.3 and above
            2856S3B, 2856S3 revision 1.4 and above
 

[jpoje]

Okay, great thanks for info. Seems I only have one more appliancelinc, the others are lamplincs. The other appliancelinc I have is a #2456S3 V4.A so should be okay. The outdoor appliancelinc I just received does not indicate "dual band" but does have an FCC ID #, so it must be dual band. Hopefully, it will be better suited for the vent fan application.

[Brian H]

V4.A should be fine to be used. Where you want it.

The Outdoor ApplianceLinc may not have a label specifying Dual Band but the FCC ID would indicate it has RF Transmitting circuits in it.

It should work fine with your fan.